Standard Shuttlecock Tube Dimensions
For a complete overview of badminton brand OEM from shuttlecock production to custom tube packaging, read our Complete Badminton Brand OEM Guide.
Shuttlecock tubes are specified by: inner diameter (ID), outer diameter (OD, determined by ID + wall thickness), and length. The ID is the critical dimension because it determines whether the shuttlecock fits.
| Tube Type | ID (mm) | Length (mm) | Capacity | Wall Thickness |
|---|---|---|---|---|
| Standard 6-pack | 42 | 190–200 | 6 shuttlecocks | 1.8–2.0mm (3-ply) |
| Standard 12-pack | 42 | 340–355 | 12 shuttlecocks | 2.0–2.5mm (4–5-ply) |
| Standard 15-pack | 42 | 420–440 | 15 shuttlecocks | 2.2–2.5mm (5-ply) |
| Junior/Nylon 6-pack | 40 | 180–190 | 6 shuttlecocks | 1.5–1.8mm (3-ply) |
| Premium 12-pack | 43 | 350–360 | 12 shuttlecocks | 2.2–2.8mm (5-ply) |
Custom Diameters: When Standard Isn't Right
Some shuttlecock brands require non-standard diameters: 38mm for training/beginner shuttlecocks with smaller skirts, 44mm for premium tournament-grade shuttlecocks, custom for branded packaging where the tube doubles as a display piece. Custom diameters require a mandrel change on the winding machine — a one-time tooling cost of $300–800 — and add 3–5 days to the sample lead time.
Wall Thickness and Crush Resistance
The number of paper plies determines wall thickness and crush resistance. A 3-ply tube (1.8mm) crushes at approximately 40–50 kg vertical compression — adequate for individual purchase and light retail display. A 5-ply tube (2.5mm) crushes at 80–100 kg — required for e-commerce fulfillment (Amazon FBA stacking, multi-case pallets) and retail environments with high product density.
For e-commerce brands, the compression spec matters more than for traditional retail. An FBA warehouse might stack product 6 cartons high, each containing 24–48 tubes. The bottom tube in the lowest carton needs to withstand the weight of 5 cartons above it plus its own contents.
Tube Weight and Shipping Cost
A 5-ply tube weighs approximately 4–6 grams more than a 3-ply tube. On a 10,000-unit order, that's an additional 40–60 kg of shipping weight. At sea freight rates of approximately $3–5/kg, the additional cost is $120–300 — notable but small relative to the product protection benefit.
For custom tube dimension specifications and samples, email support@kuzopacking.com or WhatsApp +86 153-0553-6396.